Metal particle fusion analysis for additive manufacturing using the stabilized optimal transportation meshfree method

authored by: H. Wessels, C. Weißenfels, P. Wriggers
Abstract: Selective Laser Melting (SLM) is an Additive Manufacturing (AM) process where a powder bed is locally melted. Layer by layer, complex three dimensional geometries including overhangs can be produced. Non-melted powder thereby acts as support structure. The process is held under an inert gas atmosphere to prevent oxidation. The principal machine parameters in SLM processes are the laser power, the scan rate and the laser spot radius. The powder bed is characterized by the material, the packing density and the particle size distribution. These factors define the structure of SLM finished parts. Up to date, the material and process development of SLM mainly relies on experimental studies that are time intensive and costly. Simulation tools offer the potential to gain a deeper understanding of the process–structure–property interaction. This can help to find optimal process parameters and to individualize AM manufactured parts. A continuum framework for the finite deformation phase change problem is developed. For its numerical solution the stabilized Optimal Transportation Meshfree Method (OTM) is employed. The advantage of meshfree over conventional mesh based techniques is that the treatment of particle fusion is intrinsic to the formulation. This is important to resolve the complex moving boundaries between liquid melt flow and solid metal. In a numerical example consisting of two metal powder particles, the influence of laser heating and cooling conditions on melting and consolidation is analyzed. A detailed parameter study is presented. The insight gained from the simulations may help to narrow the parameter window for further investigations.
Organisation(s): Institute of Continuum Mechanics
Type: Article
Journal: Computer Methods in Applied Mechanics and Engineering
Volume: 339
Pages: 91-114
No. of pages: 24
ISSN: 0045-7825
Publication date: 01.09.2018
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Computational Mechanics, Mechanics of Materials, Mechanical Engineering, General Physics and Astronomy, Computer Science Applications
Electronic version(s): https://doi.org/10.1016/j.cma.2018.04.042 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{f28f725b0c9843fcba2014411c41c0ae,
title = "Metal particle fusion analysis for additive manufacturing using the stabilized optimal transportation meshfree method",
abstract = "Selective Laser Melting (SLM) is an Additive Manufacturing (AM) process where a powder bed is locally melted. Layer by layer, complex three dimensional geometries including overhangs can be produced. Non-melted powder thereby acts as support structure. The process is held under an inert gas atmosphere to prevent oxidation. The principal machine parameters in SLM processes are the laser power, the scan rate and the laser spot radius. The powder bed is characterized by the material, the packing density and the particle size distribution. These factors define the structure of SLM finished parts. Up to date, the material and process development of SLM mainly relies on experimental studies that are time intensive and costly. Simulation tools offer the potential to gain a deeper understanding of the process–structure–property interaction. This can help to find optimal process parameters and to individualize AM manufactured parts. A continuum framework for the finite deformation phase change problem is developed. For its numerical solution the stabilized Optimal Transportation Meshfree Method (OTM) is employed. The advantage of meshfree over conventional mesh based techniques is that the treatment of particle fusion is intrinsic to the formulation. This is important to resolve the complex moving boundaries between liquid melt flow and solid metal. In a numerical example consisting of two metal powder particles, the influence of laser heating and cooling conditions on melting and consolidation is analyzed. A detailed parameter study is presented. The insight gained from the simulations may help to narrow the parameter window for further investigations.",
keywords = "Additive manufacturing, Implicit meshfree scheme, Optimal transportation meshfree method, Phase change modeling, Selective laser melting",
author = "H. Wessels and C. Wei{\ss}enfels and P. Wriggers",
note = "Henning Wessels acknowledges the generous support of the Fulbright association for an internship at UC Berkeley from April to September 2017. The many fruitful discussions with Tarek Zohdi, Marc Russell, Chang Yoon Park and Antonio Souto-Iglesias greatly contributed to this work.",
year = "2018",
month = sep,
day = "1",
doi = "10.1016/j.cma.2018.04.042",
language = "English",
volume = "339",
pages = "91--114",
journal = "Computer Methods in Applied Mechanics and Engineering",
issn = "0045-7825",
publisher = "Elsevier",
}